Manual Pajero 4x4 Intake and Exhaust

8/11/2019 Manual Pajero 4x4 Intake and Exhaust

1/20

15-1

INT AKE AND EXHAUST

CONTENTS 15109000311

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 INTERCOOLER AND INTERCOOLERFAN-ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2INTAKE MANIFOLD . . . . . . . . . . . . . . . . . 8

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2Intake Manifold Vacuum Check . . . . . . . . . 2

Turbocharger Supercharging Check . . . . . 2Waste Gate Actuator Check . . . . . . . . . . 3Power Relay Check . . . . . . . . . . . . . . . . . . . . . . . . . . 3

TURBOCHARGER AND EXHAUST MANIFO LD . . . . . . . . . . . . . . . . . . . . . . 12

TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . 15

EXHAUST M ANI FO LD . . . . . . . . . . . . . 18 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

EXHAUST PIPE AND MAIN MUFFLER . . . . 19


2/20

Service S pe c i f ic a t ions /15-2 INTAKE AND EXHAUST S peci al Tool/On-vehicle Se r vic e

SERVICE SPECIFIC ATIONS 15100030128

SPEC IAL TOO L 15100060172

ON-VEHICLE SERVICEINTAKE MANIFOLD VACUUM CHECK

15100180236

Refer to GROUP 11A

TURBOCHARGERCa uti on

On-vehicle Service

SUPERCHARGING CHECK15100100102

Conduct the driving test in a location where driving a full acceleration can be done with safety. Two per son should be in the vehicle when the test is conducted; the person in the passenger seat should read the indic a t ions shown by the pressure m e t e r .1. Remove the boost compensator hose from the fuel

injection pump, and install a pressure gauge as shown in the illustration.Drive at full-throttle acceleration in second gear and then measure the supercharging when the engine speed in about 3,000 r/min.When the indicated supercharging does not become positive pressure, check the following items.

2.

3.

Malfunction of the waste gate actuator. Leakage of supercharging pressure.

Malfunction of the turbocharger.4. When the indicated supercharging is 84 kPa or more,supercharging control may be faulty, therefore check the followings. Disconnection or cracks of the waste gate actuator

rubber hose.Malfunction of the waste gate actuator.Malfunction of the waste gate valve.

Tool Number Name Use

MD998770 Oxygen sensor wrench

Removal/Installation of oxygen sensor

Items Standard value Limit

Waste gate actuator activation pressure kPa Approx. 83

Intake air temperature switch C OFF (no continuity) 55 or less

ON (continuity) 57

or

more

Manifold distortion of the installation surface mm 0.15 or less 0.20


3/20

15-3INT AKE AND EXHAUST On-vehicle S e r vice

WASTE GATE ACTUATOR CHECK 15100120078

1. Connect a manual pump (pressure-application type) to nipple.While gradually applying pressure, check the pressure that begins to activate (approx. 1 mm stroke) the waste gate actuator rod.

Standard value: Approx. 83 kPa Ca uti on In order to avoid damage to the diaphragm, do not apply a pressure of 91 kPa or h ighe r .If there is a significant deviation from the standard value, check the actuator or the waste gate valve: replace i necessary.

2.

3.

POWER RELAY CHECK 15100620011INTERCOOLER FAN MOTOR RELAY CONTINUITY CHE CK

Battery voltage Terminal No.

1 3 4 5

Power is not supplied

Power is

supplied


4/20

15-4 INTAKE AND EXHAUST A i r C leaner

AIR CLE ANE RREMOVAL AND INST ALLA TION

15100210126

8.8 Nm 4 Nm 5 7

8.8 Nm 9

1013

12

4

wit h

38.8 Nm 8.8 Nm

4 Nm

12 14

8.8 Nm

13 892 Nm 7

4 Nm

8.8 Nm 1

8.8 Nm

4 Nm

8.8 Nm 6

11 214

Removal st ep s 1. Breather hose connection2. Air intake hose3. Resonator

4. Resonator 5. Air frow sensor assembly 6. Air intake hose 7. Air cleaner cover8. Bolt

9. Air cleaner element10. Air duct

11. Air duct

12. Pre-cleaner assembly

13. Air cleaner body14. Air cleaner bracket


5/20

15-5INTAKE AND EXHAUST Intercooler and Inter cool er Fan -ECU

INTERCOOLER AND INTE RCOOL ER F A N-ECU 15100420079REMOV AL AND INST ALLA TION

39 Nm

64

1

729 Nm

5

9

9 Nm

Intercooler fan-ECU removal st ep s 1. Scuff plate2. Cowl side trim3. Intercooler fan-ECU

Intercooler removal s t e p s 4. Intake air temperature switch

connector5. Intercooler fan motor connector6. Air hose B connection (Intake

manifold side)7. Air hose A-2 connection (Turbochar-

ger side)8. Intercooler and bracket assembly


6/20

15-6 INTAKE AND EXHAUST Inter cool er and Intercooler Fan -ECU

DISASSEMB LY AND REASSEMB LY 15100660020

64 9 Nm 1

6 Nm

105

6 Nm

79 Nm 3

29 Nm

9

8

Disassembly st

ep s 1. Air hose A-22. Blanch tube3. Blanch tube bracket4. Intercooler cover5. Air hose A-1

6. Air hose B7. Intake air temperature switch8. Intercooler bracket9. Fan and motor assembly

10. Intercooler

INSPECTION 15100430027 Check the intercooler fins for bending damage or foreign

matter.Check the intercooler hoses for cracking, damage or wear.


7/20

15-7INTAKE AND EXHAUST Intercooler and Intercooler Fan -ECU

INTAKE AIR TEMPERATURE SWITCH CHECK15100630014

1. Immerse the intake air temperature switch in the hot water shown in the figure.

2. When changing the water temperature, check for continuity between the terminals with the circuit tester.Standard va lue :

(Temperature at point B)

Temperature Continuity

Less than 55 C(Temperature at point A)

OFF (No continuity)

More than 57 C ON (Continuity)B

ON

OFF Water temperature

A


8/20

15-8 INTAKE AND EXHAUST Intake Manifold

INTAKE MANIFOLD 15100300663REMOVAL AND INST ALLA TION

18 Nm 22 Nm 9 Nm 10 12 Nm

10 12 Nm 17 20 Nm

412

1118 Nm

5

17 20 Nm

7 9 Nm 6

16

91

1518 Nm 2

1824 Nm 17

8 13

1918 Nm

18 Nm

14

10 3 35 Nm

Removal st ep s 1. Ignition coils2. Brake booster vacuum hose

connection

3. PCV

hose connection4. Crankshaft position sensor and

cam position sensor connector5. Accelerator cable bracket6. Ignition power transistor7. Water outlet fitting bracket8. Water pump stay9. Vacuum hose connection

10. Fuel pipe connection11. Solenoid valve and vacuum hose

assembly

12. EGR

valve13. EGR pipe connection14. Surge tank stay15. Throttle cable connection16. Air intake fitting17. Air intake fitting gasket18. Upper intake manifold

} D] 19. Surge tank gasket

Post-installation Oper at ion Throttle Body installation (Refer to GROUP 13A

Throttle Body.)

Pre-removal Oper at ion Fuel Discharge Prevention (Refer to GROUP 13A

On-vehicle Service.) Throttle Body Removal (Refer to GROUP 13A

Throttle Body.)


9/20

m

15-9INT AKE AND EXHAUST Intake Manifold

22 12 Nm

23

219 N

2220 23 Nm

5 Nm 20

24

26

24

25

} C ] 20. High-pressure fuel hose} C ] 21. Fuel pressure regulator

22. Injector connector23. Injector and delivery pipe assembly] A} 24. Water hose connection

} B] 25. Intake manifold} A ] 26. Intake manifold gasket

REMOV AL SERVICE POINT] A} INJECTOR AND DELIVERY PIPE

REMOV A L A SSEM BLY

Remove the fuel rail (with the injectors attached to it.)Ca uti on Care must be taken when removing the fuel rail not t o drop the inje c t or .

O-ring 23

20

23 21

Engine oil


10/20

15-10 INT AKE AND EXHAUST Intake Manifold

INSTALLATION SERVICE POINTS} A ] INTAKE MANIFOLD GASKET INST ALL ATIONInstall the gasket with the protrusions in the position illustrated.

} B] INTAKE MANIFOLD INST ALLATIONTighten the nuts by the following procedure.

} C] FUEL PRESSURE REGU L ATOR/HIGH-PRESSURE FUEL HOSE INST ALL ATION

When connecting the fuel pressure regulator and the high- pressure fuel hose to the fuel rail, apply a small amount o new engine oil to the O-ring. Then insert the high-pressure fuel hose, being careful not to damage the O-ring.Ca uti on Be careful not to let any engine oil get into the fuel r a il .

} D] SURGE TANK GASKET INST ALL ATIONInstall the gasket with the protrusion in the position illustrated.Front

Protrusion

Fuel pressure regulator

Fuel rail

High-pressure fuel hose

Fuel rail

Order Mounting Nuts Tightening Torque

1 Right-bank nuts 7 Nm

2 Left-bank nuts 20 23 Nm

3 Right-bank nuts 20 23 Nm

4 Left-bank nuts 20 23 Nm5 Right-bank nuts 20 23 Nm

Right bank Left bank

Front

Intake manifold

Protrusion Front

Protrusion


11/20

15-11INTAKE AND EXHAUST Intake Manifold

INSPECTION 15100370039Check the following points; replace the part if a problem is found.

INTAKE MANIFOLD CHE CK 1.2.

Check for damage or cracking of any part.Clogging of the negative pressure (vacuum) outlet port,or clogging of the gas passages.Check deflection of installation surface with straight edge and feeler gauge.Standard value: 0.15 mm or less

Limit: 0.20 mm

3.


12/20

Turbocharger and Exh au st Manifold 15-12 INTAKE AND EXHAUST

TURBOCHARGER AND EXHAUS TREMOVAL AND INST ALLA TION

M ANI FO LD 15100450061

19 Nm 3

4 5 18 Nm 9 Nm 25 Nm 18 Nm

79 Nm

9 Nm 6

42 Nm 17 Nm

8 12118 Nm

14

10

112

9 Nm 30 Nm

9

13 43 Nm

15

Removal st ep s

1. Front exhaust pipe connection2. Boost hose3. Waste gate actuator4. Vacuum hose5. EGR valve6. EGR pipe7. Heat protector A8. Intake manifold

9. Heat protector10. Water pipe B11. Water pipe A12. Oil pipe13. Oil return hose connection14. Exhaust manifold and turbocharger

assembly15. Intake and exhaust manifold gasket

Pre-removal and Post-installation Oper at ion Engine Coolant Draining and Supplying Intercooler Removal and Installation (Refer to P. 15-5.) Air Cleaner Cover and Air Intake Hose Removal and

Installation (Refer to P. 15-4.)


13/20

Turbocharger and Exh au st 15-13INT AKE AND EXHAUST Ma nif old

60 Nm

17

2216

2023

19

9 Nm 21

18 60 Nm

12 15 Nm

16. Exhaust fitting17. Exhaust fitting gasket18. Oil-return pipe19. Oil-return pipe gasket20. Exhaust manifold21. Turbocharger gasket

} A ] 22. Turbocharger assembly23. Heat protector

INST ALLA TION SERVICE POINT} A ] TURBOCHARGER ASSEMBLY INST ALL ATION1. Clean the alignment surfaces shown in the illustration.2. Supply clean engine oil from the oil pipe mounting hole

of the turbocharger assembly.Ca uti on When cleaning, take care that no foreign material g e t s into the engine coolant or oil passages ho le.


14/20

Turbocharger and Exh au st INTAKE AND EXHAUST Manifold 15-14

INSPECTIONTURBOCHARGER ASSEMBLY CHEC K

15100640017

Visually check the turbine wheel and the compresso wheel for cracking or other damage.Check whether the turbine wheel and the compresso wheel can be easily turned by hand.Check for oil leakage from the turbocharger assembly.

Check whether or not the waste gate valve remains open. If any problem is found, replace the part after disassembly.

OIL PIPE AND OIL RETURN PIPE CHE CK 15100650010Check the oil pipe and oil return pipe for clogging, bending,or other damage. If there is clogging, clean it.

EXHAUST MANIFOLD CHE CK Damage or cracking of any part.

15100340108

Compressor wheel


15/20


16/20

15-16 INT AKE AND EXHAUST Tu r bocharg er

] B} TURBINE WHEEL ASSEMBLY REMOV AL Remove the turbine wheel assembly, striking thecircumference of the compressor cover with a plastic hammer The turbine wheel assembly may be a little hard to remov due to an O-ring put on the outer circumference.

CLEANING1. Use a clean cleaning oil commercially available. Do no

use corrosive cleaning oils as they could damage to some parts.

2. Use a plastic scraper or hard brush to clean aluminum parts.

REASSEMBLY SERVICE POINTS} A ] O-RING INST ALLATION

Apply a light coat of engine oil to a new O-ring and fit in the turbine wheel assembly groove.Ca uti on When installing the O-ring, use care not to damage i t .

A damaged O-ring causes oil leaks .

} B] TURBINE WHEEL A SSEM BLY1. Apply a light coat of engine oil to the periphery of the

O-ring.2. Install the turbine wheel assembly to the compressor cover

in relation to the dowel pin.Ca uti on Use care not to damage the blades of turbine wh ee l and compressor wh eel .

} C] SNAP RING INST ALLATIONLay the assembly with the compressor cover facing down and fit the snap ring.Ca uti on Fit the snap ring with its chamfered side facing up .

Snap ring edge Chamfered

Turbine wheel assembly

Compressor cover

Dowel pin hole

Dowel pin

O-ring

Turbine wheel assembly


17/20

15-17INT AKE AND EXHAUST Tu r bocharg er

} D] TURBINE HOUSING INST ALLATIONInstall the turbine housing in relation to the dowel pin.Ca uti on Use care not to damage the blades of turbine wh ee l.

} E] COUPLING INST ALLATIONInstall the coupling and tighten to specified torque.

INSPECTIONTURBINE HOUSING1. Check the housing for traces of contact with the turbine

wheel, cracks due to overheating, pitching, deformation and other damage. Replace with a new turbine housing if cracked.

2. Operate the waste gate valve lever manually to chec that the gate can be operated and closed smoothly.

15100610018

COMPRESSOR COVERCheck the compressor cover for traces of contact with the compressor wheel and other damage.TURBINE WHEEL ASSEM BLY1. Check the turbine and compressor wheel blades for bend,

burr, damage, corrosion and traces of contact on the back side and replace if defective.Check the oil passage of the turbine wheel assemblyfor deposit and clogging.In the case of water cooled type, check also the wate passage for deposit and clogging.Check the turbine wheel and compressor wheel for ligh and smooth turning.

2.Compressor

3.

4.

OIL PIPE/OIL RETURN PIPECorrect or replace the oil pipe and oil return pipe if clogged,collapsed, deformed or otherwise damaged.

Oil passage

Turbine wheel

Water passage

wheel

Traces for contact

Coupling

Dower pin

Dower pin hole


18/20

15-18 INTAKE AND EXHAUST E xhaust Mani f ol d

EXHAUST MANIFOLD 15100330587REMOV AL AND INST ALLA TION

112 15 Nm

42

18 Nm 44 Nm

59 Nm 344 Nm 5

7 6

12 15 Nm

Removal st ep s 1. Heat protector (R.H.)2. Exhaust manifold (R.H.)3. Exhaust manifold gasket (R.H.)4. EGR pipe

5. Heat protector (L.H.)6. Exhaust manifold (L.H.)7. Exhaust manifold gasket (L.H.)

INSPECTION 15100340160Check the following points; replace the part if a problem is found.EXHAUST MANIFOLD CHE CK 1. Check for damage or cracking of any part.2. Using a straight edge and a feeler gauge, check for

distortion of the cylinder head installation surface.Standard value: 0.15 mm or less

Limit: 0.20 mm

Pre-removal and Post-installation Oper at ion Front Exhaust Pipe Removal and Installation

(Refer to P.15-19.) Air Cleaner Removal and Installation

(Refer to P.15-4.)

Battery and Battery Tray Removal and Installation Engine Oil Dipstick Guide Removal and Installation


19/20

15-19INTAKE AND EXHAUST E xhaust P ipe a nd Main Muffler

EXHAUST PIPE AND MAIN MUFFLE R 15100540461REMOV AL AND INST ALLA TION

1617

13 Nm 213 Nm 14 115

413 Nm 510 344 Nm 6

13 49 Nm 49 Nm

49 Nm 13 Nm 425 Nm 5

107 13

Nm 813 25 Nm 49 Nm

25 Nm

1617

13 Nm 211413 Nm 15

4 3513 Nm 25 Nm

49 Nm

25 Nm 13 Nm 45749 Nm 13 Nm 11 7849 Nm

Main muffler removal st ep s 1. Tail pipe2. Hanger3. Main muffler4. Hanger5. ProtectorCenter exhaust pipe removal s t e p s 6. Center exhaust pipe7. Hanger8. Protector

9. Catalytic converter Front exhaust pipe removal s t ep s

] A} } A ]

10.

Oxygen

sensor

11. Front exhaust pipe

12. Front exhaust pipe (R.H.) 13. Front exhaust pipe (L.H.) 14. Hanger15. Protector16. Front floor heat protector B17. Front floor heat protector A

Pre-removal and Post-installation Oper at ion Front Under Cover Removal and Installation


20/20

15-20 INTAKE AND EXHAUST Exhaust Pipe and Main Muffler

REMOVAL SERVICE POINT] A} OXYGEN SENSOR REMOV A L Use special tool to remove the oxygen sensor.

INSTALLATION SERVICE POINT} A ] OXYGEN SENSOR INST ALL ATIONUse special tool to install the oxygen sensor.

MD998770

Documents

Manual Pajero 4x4 Intake and Exhaust